US5414587A - Surge suppression device - Google Patents

Abstract

A surge suppression device which fits over the end of an electrical plug and permits normal mating of the plug with the female receptacle. In the preferred embodiment, the device includes a body of metal-oxide varistor (MOV) material where one pin is connected to one plate on the MOV and another plug pin is connected to an opposing plate on the MOV. The MOV breaks down when experiencing excessive voltage levels to shunt potentially damaging voltages between the plug pins thereby preventing the spikes from reaching the protected equipment.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 938,111, filed Aug. 31, 1992 now U.S. Pat. No. 5,290,191, which is a continuation-in-part of U.S. Ser. No. 895,148 filed Jun. 5, 1992, now U.S. Pat. No. 5,181,859, which is a continuation of U.S. Ser. No. 694,262 filed Apr. 29, 1991, now abandoned. This application is also related to U.S. Ser. No. 07/998,354, filed Dec. 30, 1992; U.S. Ser. No. 07/998,332, filed Dec. 30, 1992; U.S. Ser. No. 08/087,638, filed Jul. 1, 1993; U.S. Ser. No. 08/054,658, filed Apr. 23, 1993; and U.S. Ser. No. 08/139,594, filed Oct. 20, 1993.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to electrical surge suppressing techniques and, more particularly, to a device for reducing electrical power line noise and interference.

2. Discussion

Modern commercial electrical equipment can be damaged by noise, voltage spikes and electromagnetic interference (EMI) which is conducted through the power lines. Several of the present devices used for suppression of line noise include surge suppressor power strips, gang boxes and active power conditioners. Typically, existing devices for surge suppression are bulky and occupy considerable space around the electronic equipment. They also generally require an additional power plug, receptacle and an electrical enclosure to house the plug, the receptacle and the suppression circuitry. A commercially available example of this type of construction is the "Heavy-Duty Voltage Spike Protector" by Archer.

Other problems are found in the prior art designs which are due, in part, because they use individual wire leads up to several inches long. These additional wires contain a measurable and undesirable impedance which reduces the effectiveness of the suppression. In addition, the large enclosures and plug/receptacle hardware design utilized in prior art constructions also increase production and distribution costs, as well as imposing a space penalty on the end user.

A need therefore exists for an improved implementation concept for power plug surge suppressor that eliminates the extraneous hardware and improves the suppression performance.

SUMMARY OF THE INVENTION

In accordance with the teachings of the present invention, a device including voltage transient limiting material thereon is provided with a series of holes aligned with the pins in the associated electrical plug. The device can be slipped over the male pins and is thin enough to allow the plug to be mated with a female power receptacle in the normal fashion, without interference from the device. The device has contacts that make connection between selected pins in the power plug and the transient limiting material without requiring long wire lead lengths.

The installation requires no modification to the host hardware, can be accomplished very quickly and does not interfere with the mechanical or electrical integrity of the host connectors. The functionality of the surge suppression is contained within the confines of the device, unlike prior art approaches which require the bulk of the functionality to be placed in an external enclosure outside of the electrical plug. As a result, the present invention eliminates the extraneous parts and eliminates the extra lead lengths, thereby improving the suppression performance and avoiding the need for space outside of the mated plug and receptacle to perform its function. Production and distribution costs are relatively small due to the elimination of extraneous parts and a major reduction in size and weight.

BRIEF DESCRIPTION OF THE DRAWINGS

Still other advantages of the present invention will become apparent to those skilled in the art after a study of the specification and by reference to the drawings in which:

FIG. 1 is an exploded perspective view of a surge suppression device of this invention, an electrical plug and receptacle;

FIG. 2 is a plan view of one embodiment of the surge suppression device which provides surge protection between the hot and neutral prongs of an AC electrical plug;

FIG. 3 is an exploded view of the device of FIG. 2;

FIG. 4 is a cross sectional view taken along thelines 4--4 of FIG. 2;

FIG. 5 is a view, similar to FIG. 4, showing the surge suppression device sandwiched between the electrical plug which is mated with the female receptacle;

FIG. 6 is an exploded perspective view of another embodiment of this invention, for use with a three-pronged electrical plug;

FIG. 7 is a plan view of the surge suppression device embodiment of FIG. 6;

FIG. 8 is a cross sectional view taken along thelines 8--8 of FIG. 7;

FIG. 9 is a perspective view of still another embodiment of the surge suppression device of this invention;

FIG. 10 is an enlarged partial perspective of certain components of the device of FIG. 9;

FIG. 11 is an electrical schematic diagram of the components in the device design of FIG. 9;

FIG. 12 is a plan view of still another embodiment;

FIG. 13 is a cross sectional view taken along thelines 13--13 of FIG. 12; and

FIG. 14 is a plan view of another embodiment, similar to the embodiment of FIG. 12, for use with three-pronged electrical plugs.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

It should be understood from the outset that the present invention will be described in connection with a few limited examples which illustrate the best mode of practicing the invention at the time that this application was filed. However, various modifications will become apparent to those skilled in the art after having the benefit of studying the text, drawings and claims which follow this detailed specification. Additional embodiments will also come to mind by reference to the aforementioned U.S. Ser. No. 938,111, which is hereby incorporated by reference.

FIGS. 1-5 illustrate one embodiment of the surge suppression device of this invention. FIG. 1 illustrates a surgesuppression insert device 10 used in connection with a conventional two-prongedAC power plug 12 and 120volt AC receptacle 14.Plug 12 can be used to supply power overcable 26 toequipment 28 which can be a large variety of government, industrial, commercial and residential electrical/electronic subsystems. For example, thedevice 10 can be quickly added in a power cable on a piece of factory equipment to non-intrusively eliminate noise on power lines caused by motors in the plant. Alternatively, thesurge suppression device 10 can be added to power tools, portable electronics and computers without adding undue weight or bulk.

In FIG. 1,plug 12 includes conventionalrectangular male pins 16 and 18, referred to as the hot and neutral conductive pins.Male pins 16, 18 typically are about 0.7 inches long and are normally respectively inserted directly into matingfemale sockets 22, 24 inreceptacle 14. When directly mated, the power fromreceptacle 14 often has noise or voltage transients associated with it. As is known, normal line voltage is approximately 115-120 volts AC. Voltage transients of much higher voltage levels, known as surges, are often experienced and, if not suppressed, can damage theequipment 28 powered byplug 12. In accordance with the present invention,device 10 serves to suppress these voltage transients.

The construction details fordevice 10 are better shown in FIGS. 2-5. Substantially the entire body of the device is made of a voltagetransient limiting material 30 which is a composition or combination of materials which operate to prevent excessive voltages from damaging theelectrical device 28 connected to theplug 12. Presently preferred materials are ones having dielectric characteristics and include metal oxide dielectric materials, such as zinc oxide, which is designed so that it has a breakdown voltage that is above normal line voltage (e.g., 120 volts) yet low enough that the protection is experienced at high voltage transients. For example, surge suppressors formed from zinc oxide dielectric materials can have a breakdown voltage of approximately ±400 volts. Devices of this general type are known as metal oxide varistors (MOV's) and are commercially available from various sources such as Harris Semiconductor as model No. V131CA32.MOV body 30, in this embodiment, is formed in the shape of a thin planar wafer whose perimeter is preferably coextensive with or smaller than the periphery of theplug end face 32.

Amajor face 34 of theMOV body 30 has aconductive plate 36 thereon. Similarly, aconductive plate 38 is formed on anopposite face 40 of thebody 30.Openings 42, 44 are formed in thebody 30 to receive the hot andneutral pins 16, 18, respectively ofplug 12.

Provision is made for making electrical contact between thepins 16 and 18 and theplates 36 and 38, respectively, when thedevice 10 is in use. In the illustrated embodiment, an array ofbendable finger contacts 48 are formed fromconductive plate 36 and protrude intoopening 42. Similarly,contacts 50 extend intoopening 44 to make electrical contact to plate 38. Theplates 36, 38 andcontacts 48, 50 can be formed from a conductive pattern of brass approximately 5 mils thick which is bonded tobody 30 by solder or the like.

The exterior ofbody 30 is covered with a suitable insulatinglayer 52 such as Kapton while leavingcontacts 48 and 50 exposed.

As shown best in FIG. 5, thedevice 10 is sufficiently thin that theplug 12 can be mated with thereceptacle 14 in the normal fashion, with thedevice 10 being sandwiched therebetween. Typically, the total thickness ofdevice 10 should be less than about 0.1 inch or less than about 15% of the length ofpins 16, 18. TheMOV body 30 itself is about 0.04 to 0.07 inch thick.

In use, the user slips thedevice 10 over the male pins of theplug 12. Anoptional adhesive layer 54 may be provided to adhere thedevice 10 to theend face 32 ofplug 12.Pin 18 is thus connected to plate 36 by way ofcontacts 48. Similarly, plugpin 16 is connected to plate 38 bycontacts 50. It will be appreciated that thepins 16 and 18 are thereby electrically coupled together through thedielectric body 30 via the overlappingplates 36, 38. Theplug 12 is then inserted into thereceptacle 14 in the normal fashion, with thedevice 10 being sandwiched therebetween.

When normal line voltage is being provided byreceptacle 14, theMOV body 30 presents a very high impedance betweenpins 16 and 18. There is effectively an open circuit betweenpins 16 and 18 and, as a result, the voltage fromreceptacle 14 passes toequipment 28 substantially unaltered. However, if a voltage surge is experienced which exceeds the breakdown voltage of the MOV body 30 (e.g., above 400 volts) the MOV breaks down and provides a conductive path betweenpins 16 and 18. Thus, there is effectively a short circuit provided betweenpins 16 and 18 which shunts the potentially dangerous voltage levels from thedevice 28. This conductive path disappears when the line voltage returns to normal levels (e.g., below the breakdown voltage of body 30).

The embodiment of FIGS. 2-5 provides protection from a differential voltage surge which appears between the hot andneutral pins 16 and 18. In contrast, the embodiment of FIGS. 6-8 provide a common-mode protection for a three-pronged electrical plug which includes a ground male pin 56 in addition to the previously discussed hot andneutral pins 16 and 18. In such manner theelectrical equipment 28 is protected from voltage surges between any combination of the pins, i.e., between theground pin 54 and thehot pin 16, between theground pin 54 and theneutral pin 18, as well as between the hot andneutral pins 16 and 18.

In this later embodiment, thebody 60 of metal oxide varistor material is split into three spaced,co-planar parts 62, 64 and 66. The topconductive plate 68 is split into twoparts 70 and 72. The bottomconductive plate 74 is separated into twoparts 76 and 78.Part 72 includes asplit contact 80 for making electrical connection to the lower part of theneutral pin 18.Part 70 includes afull contact portion 82 for making contact with the entirety of thehot pin 16.Part 76, on the other hand, has asplit contact portion 84 for making electrical contact to the upper portion ofneutral pin 18.Part 78 oflower plate 74 includes afull contact area 86 for engaging theground pin 54.

As shown most clearly in FIGS. 6, 7 and 8, there is a spacing betweenparts 62, 64 and 66 ofMOV body 60 when thedevice 90 is assembled together. Likewise,parts 70 and 72 ofplate 68 are spaced from each other. Analogously,parts 76 and 78 ofplate 74 are spaced apart. As in the previous embodiment, the exterior of thedevice 90 is covered with aninsulated coating 92. When assembled,cutouts 96 and 98 inbody 60 cooperate to form a slot through which theneutral pin 18 passes.Cutouts 100 and 102 similarly form aslot 104 through which thehot pin 16 passes. Opposingarcuate recesses 108 and 110 cooperate to form an opening 112 through which theground pin 54 passes.

Upper plate 68 further includes acutout 114 which cooperates withcontact 80 to form an opening through which theneutral pin 18 passes.Cutout 114 is large enough so that thepin 18 does not make electrical contact toconductive part 70. Instead, pin 18 only makes contact with thefingers 80 ofpart 72. On the other hand, bendablefinger contact area 82 makes full contact with thehot pin 16. Likewise,bendable finger contacts 86 make electrical connection to theground pin 54.

When thedevice 90 is sandwiched between the mated plug and receptacle, the multi-parted components of the device cooperate to provide the common-mode protection. Protection from ground to hot transients is provided by way ofMOV part 66 which is sandwiched betweenconductive part 70 viacontacts 82 andconductive part 78 viacontact area 86. Ground to neutral transient protection is provided by way ofMOV body part 64 which is sandwiched betweenconductive portion 72 viasplit contact area 80 andconductive part 78 which is electrically connected to groundpin 54 viacontacts 86. Hot to neutral transient protection is provided by way ofbody part 62 which is sandwiched between conductive part 70 (via contact 82) and thehalf contact 84 onconductive part 76. In such manner, there are three separate MOV circuit paths for respectively protecting against voltage transients appearing as any combination of the male pins of the plug.

The embodiment of FIGS. 9 to 11 include the provision of a visual indicator which will inform the user about the operational status of thesurge suppression device 140. This feature of the invention will be described in connection of a two-pronged embodiment similar to that illustrated in FIGS. 1-5. Consequently, like reference numerals will be used in the description thereof. However, it should be understood that this feature has applicability to all embodiments.

In FIGS. 9 to 11, astatus indicator light 142, adiscrete resistor 144 and fuse 146 are provided in apocket 148 in an upper edge of the device. An insulatinglayer 150 isolates thehot pin contact 152 and connectingtrace 154 from the hot metallayer forming plate 156 on theMOV body 30. L-shapedtrace 154 extends fromcontact 152 into thepocket 148 to make connection with one end offuse component 146. An opposite end offuse 146 is connected by way of L-shapedtrace 158 to thehot metal plate 156.Trace 158 also makes electrical contact to one end ofresistor 144 which, in turn, is connected by way oftrace 160 to one end ofindicator light 142. An opposite end oflight 142 is electrically connected by way of a solder joint or the like 162 to theneutral metal plate 164 which, in turn, is coupled toneutral pin contact 165.

It should now be appreciated that the connection thus described forms the electrical schematic shown in FIG. 11. Fuse 146 is calibrated to burn out at a level well below the maximum current rating of theMOV body 30, for example, at 10 amperes. If thedevice 140 is subjected to an abnormally high current, thefuse 146 will blow thereby removing power from the light 142. Thus, the user will be provided with a visual indication that thedevice 140 is no longer functional.

The embodiments of FIGS. 12-14 illustrate designs using discrete components, as compared to the monolithic approach shown in the previous figures. Functionally, the embodiment of FIGS. 12-13 are equivalent to the embodiment of FIGS. 1-5. Similarly, the embodiment of FIG. 14 is functionally equivalent to that of the embodiment of FIGS. 6-8.

Thedevice 170 in FIGS. 12-13 include aplastic housing 172 incorporating adiscrete MOV disk 174.Neutral contacts 176 are provided for making electrical connection to theneutral plug pin 18.Contacts 176 are connected to an upper face ofMOV disk 174 by way of trace 178. Contact 182 forhot plug pin 16 is connected by way oftrace 184 to an opposite surface ofMOV disk 174. The geometric relationship betweensurge suppression device 170 and a two-pronged plug 12 is illustrated in FIG. 12.

Asurge suppression device 186, incorporating both differential and common-mode protection, is illustrated in FIG. 14. It includes three separatedMOV disks 188, 190 and 192 contained inplastic housing 194.Contacts 196, 198 and 200 are provided for making electrical connection to the neutral, hot and ground plug pins.Trace 202 makes electrical connection betweenneutral contact 196 and one face ofMOV 188.Trace 204 makes electrical connection between an opposite face ofMOV 188 andhot contact 198.Trace 206 makes electrical connection between one surface ofMOV 192 andhot contact 198.Trace 208 makes electrical connection between an opposite face ofMOV 192 andground plug contact 200.Trace 210 makes electrical connection betweenground contact 200 and one face ofMOV 190.Trace 194 makes electrical connection between an opposite face ofMOV 190 andneutral contact 196. The geometric relationship betweendevice 186 and a three-pronged plug 12' is illustrated in FIG. 14.

Those skilled in the art can now appreciate the present invention offers significant advantages over surge suppressor devices of the prior art. It can be quickly and easily installed. It eliminates extraneous and bulky parts resulting in a major reduction in size and weight. From an aesthetic point of view, the surge suppression function is accomplished less obtrusively than many existing alternatives, because its functionality is contained within a device which resides largely within the confines of the periphery of the plug. In addition, the present design eliminates extraneous wire lead lengths thus improving performance.

As noted from the outset, the invention has been described in connection with a few particular examples. However, various modifications and other applications will become apparent to the skilled practitioner after having the benefit of studying the specification, drawings and following claims.

Claims (28)

What is claimed is:

1. A surge suppression device for protecting electrical equipment from damage, the electrical equipment being supplied with power from a plug having a plurality of male pins which mate with sockets in a female electrical receptacle, said device comprising:

a structure sufficiently thin so as to fit between adjacent faces of the plug and female receptacle while permitting the pins to mate with the sockets;

said structure having holes therein aligned with the pins in the plug, the structure being insertable over the pins so that the pins extend through the holes;

first contact means for making electrical contact with one of the pins as it extends through a hole in the structure;

second contact means for making electrical contact with a second pin as it extends through a second hole in the structure;

said structure including a body made of voltage transient limiting material having opposing first and second faces;

said first contact means being electrically connected to the first face;

said second contact means being electrically connected to the second face; and

whereby the device is insertable over the pins of the male plug and the body provides surge suppression protection for the electrical equipment when the plug is mated with the female receptacle.

2. The device of claim 1 wherein the body is made of a metal oxide varistor material.

3. The device of claim 2 wherein the material is zinc oxide.

4. The device of claim 1 which further comprises a first plate on the first face of the body and a second plate on the second face of the body.

5. The device of claim 4 wherein the first and second plates are substantially coextensive with the first and second faces of the body.

6. The device of claim 5 wherein at least one hole passes through the body and at least one plate.

7. The device of claim 6 wherein the faces of the body are coated with an insulating material.

8. The device of claim 1 wherein the device lies essentially flush with the adjacent face of the plug.

9. The device of claim 1 which further comprises:

adhesive means for adhesively securing a surface of the device against an end face of the plug.

10. The device of claim 1 wherein the structure comprises a planar wafer of voltage transient limiting material which substantially corresponds to the shape of the perimeter of the end plug and has a thickness which is less than about 15% of the length of the pins of the plug.

11. The device of claim 1 wherein said contact means comprises a plurality of bendable fingers.

12. The device of claim 1 which further includes visual means for indicating that the device is operational.

13. The device of claim 12 wherein the visual means includes a fuse and a lamp connected between one of the contact means and to one face of the body.

14. The device of claim 1 wherein the first and second contact means comprise a plurality of bendable fingers extending into the holes for making wiping contact with the pins.

15. The device of claim 1 for use with a three-pronged plug having neutral, hot and ground pins, said device further comprising:

a plurality of spaced bodies of metal oxide varistors (MOV);

a plurality of spaced plates on opposing faces of the plurality of MOV bodies; and

connection means for providing common-mode protection from voltage transients appearing between any combination of the pins.

16. The device of claim 15 wherein the connection means include a split contact arrangement where the same pin is electrically connected to one plate on one face of an MOV body and to another plate on an opposite face of another MOV body.

17. A surge suppression device for protecting electrical equipment from damage, the electrical equipment being supplied with power from a plug having a plurality of male pins which mate with sockets in a female electrical receptacle, said device comprising:

a planar body of metal oxide varistor (MOV) material, said body having first and second opposing major faces, said body having a plurality of holes therein aligned with the pins in the plug;

first contact means on the first face of the MOV body for making electrical contact with one of the pins as it extends through a hole in the body;

second contact means on the second face of the MOV body for making electrical contact with a second pin as it extends through a second hole in the body;

a first metallic plate on the first face of the MOV body electrically connected to the first contact means;

a second plate on the second face of the MOV body electrically connected to the second contact means; and

said device being removably insertable over the pins of the male plug with the pins extending through the holes in the device, said device being sufficiently thin to fit between the plug and female receptacle while permitting the pins to mate with the sockets, whereby the device provides surge suppression protection for the electrical equipment when the plug is mated with the female receptacle.

18. The device of claim 17 wherein the device lies essentially flush with an end face of the plug and has a perimeter essentially coextensive with the perimeter of the plug.

19. The device of claim 17 which further comprises:

indicator means for providing information about the operational status of the device.

20. The device of claim 19 wherein said indicator means comprises a fuse and an indicator lamp which lights during proper operation of the device, with the fuse being blown to extinguish the lamp when the device is subject to abnormal current levels.

21. The device of claim 20 wherein the fuse and the light are electrically connected between the first and second contact means.

22. A surge suppression device for protecting electrical equipment from damage, the electrical equipment being supplied with power from a plug having a plurality of male pins which mate with sockets in the female electrical receptacle, said device comprising:

a non-conductive, generally planar housing that is sufficiently thin so as to fit between the plug and the female receptacle while permitting mating engagement therebetween, said housing having holes therein aligned with the pins in the plug, with the housing being removably insertable over the pins so that the pins extend through the holes;

at least one body of voltage transient limiting material within the housing;

first contact means for making electrical contact with one of the pins as it extends through a hole in the housing and one face of the body of voltage transient limiting material;

second contact means for making electrical contact between a second pin as it extends through a second hole in the housing and an opposite face of the body Of voltage transient limiting material; and

wherein the housing is removably insertable over the pins of the male plug and the body of voltage transient limiting material provides surge suppression protection for the electrical equipment when the plug is mated with the female receptacle.

23. The device of claim 22 which further provides differential and common-mode surge suppression for the electrical equipment, said device further comprising:

first, second and third separated disks of metal oxide varistor (MOV) material contained within the housing;

three holes in the housing through which hot, neutral and ground pins of the plug extend;

neutral contact means for making electrical contact with the neutral pin as it extends through a hole;

hot contact means for making electrical contact with the hot pin as it extends through a second hole;

ground contact means for making electrical contact to the ground pin as it extends through a third hole;

first conductive means for making electrical connection between the neutral contact means and one face of a first MOV disk;

second conductive means for making electrical connection between an opposite face of the first MOV disk and the hot contact means;

third conductive means for making electrical connection between the hot contact means and one face of the second disk;

fourth conductive means for making electrical connection between an opposite face of the second MOV disk and the ground contact means;

fifth conductive means for making electrical connection between the ground contact means and one face of the third MOV disk; and

sixth conductive means for making electrical contact between an opposite face of the third MOV disk and the neutral contact means.

24. A surge suppression device for protecting electrical equipment from differential and common-mode voltage transients appearing between any combination of hot, neutral and ground pins of a plug which mate with sockets in a female receptacle, said device comprising:

first, second and third spaced bodies of metal oxide varistor (MOV) material;

first and second insulating layers on opposite faces of the first, second and third bodies for maintaining the bodies adjacent to each other in a spaced co-planar relationship;

said bodies having a plurality of holes therethrough for receiving the neutral, hot and ground pins of the plug;

neutral contact means for making electrical contact with the neutral pin as it extends through a hole;

hot contact means for making electrical contact with the hot pin as it extends through a second hole;

ground contact means for making electrical contact to the ground pin as it extends through a third hole;

first conductive means for making electrical connection between the neutral contact means and one face of the first MOV body;

second conductive means for making electrical connection between an opposite face of the first MOV body and the hot contact means;

third conductive means for making electrical connection between the hot contact means and one face of the second MOV;

fourth conductive means for making electrical connection between an opposite face of the second MOV and the ground contact means;

fifth conductive means for making electrical connection between the ground contact means and one face of the third MOV;

sixth conductive means for making electrical contact between an opposite face of the third MOV and the neutral contact means; and

said device being sufficiently thin so as to fit between the plug and the female receptacle while permitting mating engagement therebetween to thereby provide differential and common-mode surge suppression protection for electrical equipment being powered by the receptacle when the plug is mated therewith.

25. The device of claim 24 which further comprises:

first and second metallic plates on one side of the MOV bodies, the first plate having a split contact for engaging a lower portion of the neutral plug pin, said first plate lying on the first MOV body, said second plate bridging the second and third MOV bodies, said second plate including a contact for making electrical connection to the hot plug pin;

second and third conductive plates on an opposite side of the MOV bodies, said third plate lying on the second MOV and having a split contact for making electrical connection with an upper portion of the neutral plug pin, the fourth plate bridging the second and third MOV bodies, and said fourth plate including a contact for making electrical connection with the ground plug pin.

26. A method of preventing damage to electrical equipment from voltage transients, said electrical equipment being supplied with power from a plug having a plurality of male pins which mate with sockets in a female receptacle, said method comprising:

providing a device having a series of holes therein corresponding to the pins in the male plug, said device having a body made of voltage transient limiting material connected between first and second conductive members;

inserting the device onto an end face of the plug so that the pins extend through the holes with one pin being electrically connected to one conductive member and another pin being connected to the second conductive member;

inserting the male plug pins into the female receptacle sockets, with the device lying therebetween; and

using the characteristics of the body material to selectively shunt excessive voltage levels between the pins to thereby prevent damage to the electrical equipment.

27. The method of claim 26 wherein the material is a metal oxide varistor disk, and the conductive members comprise plates on opposite faces of the disk.

28. The method of claim 26 wherein the perimeter of the device lies essentially within the confines of the perimeter of an end face of the plug.

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